Vascular filter with improved strength and flexibilty

ABSTRACT

A method and apparatus for treating a patient having an obstruction in a first blood vessel through which blood normally flows in a given direction, at a location downstream of a branch point where the first blood vessel and, a second blood vessel branch off from a main blood vessel, by: blocking blood flow in the main blood vessel at a point upstream of the branch point; inserting into the second blood vessel a first filter adapted to pass blood while trapping debris resulting from removal of the obstruction; inserting an obstruction removal assembly into the first blood vessel and operating the assembly to at least partially break up the obstruction and produce debris; withdrawing the obstruction removal assembly from the patient&#39;s body; and then inserting into the first blood vessel a filter adapted to pass blood while trapping debris; then restoring blood flow in the main blood vessel.

This is a continuation-in-part of allowed U.S. application Ser. No. 10/304,067, filed on Nov. 26, 2002, now U.S. Pat. No. 7,214,237, issued on May 8, 2007, which is itself a continuation-in-part of U.S. application Ser. No. 09/803,641, filed on Mar. 12, 2002, now U.S. Pat. No. 6,485,502, issued on Nov. 26, 2002, the entire disclosures of which applications and patents are incorporated herein by reference. This application also claims the benefit of the filing dates of the following U.S. Provisional Applications: No. 60/412,071, filed Sep. 19, 2002; No. 60/417,408, filed Oct. 9, 2002; and No. ______, filed Nov. 1, 2002.

BACKGROUND OF THE INVENTION

This invention relates to medical devices, such as vascular filters to be used in a body lumen, such as a blood vessel, with improved strength and flexibility. A filter according to the invention includes a proximal frame section, a distal section and a flexible thin membrane with perfusion holes of a diameter that allows blood to pass, but prevents the movement of emboli downstream.

Both sections can be collapsed into a small diameter delivery catheter and expanded upon release from this catheter. The membrane has a proximal entrance mouth, which can be expanded, or deployed, substantially to the same size as the body lumen. It is attached to the proximal frame section, which has the function to keep the mouth of the membrane open and prevent the passing of emboli between the body lumen wall and the edge of the filter mouth.

In order to have a good flexibility, the membrane is made extremely thin. Normally this would create the risk that the membrane could tear easily, which could cause problems because emboli and pieces of the membrane would then be carried downstream from the filter site.

U.S. Pat. No. 5,885,258 discloses a retrieval basket for catching small particles, made from a slotted tube preferably made of Nitinol, a titanium nickel shape memory alloy. The pattern of the slots allows expansion of the Nitinol basket and by shape setting (heat treatment in the desired unconstrained geometry) this basket is made expandable and collapsible by means of moving it out or into a surrounding delivery tube.

In principle, a distal filter is made of such an expandable frame that defines the shape and enables placement and removal, plus a filter membrane or mesh that does the actual filtering work.

Sometimes the expandable frame and the mesh are integrated and made from a single material, for example Nitinol, as disclosed in U.S. Pat. No. 6,383,205 or US Published Application No. 2002/0095173. These filters do not have a well-defined and constant size of the holes where the blood flows through, because of the relative movement of the filaments in the mesh. This is a disadvantage, because the size of emboli can be very critical, e.g. in procedures in the carotid arteries. Further the removal of such a filter, accompanied by a reduction of the diameter, may be critical because emboli can be squeezed through the mesh openings with their changing geometry.

A much better control of the particle size is achieved with a separate membrane or filter sheath, which has a well-defined hole pattern with for example holes of 100 microns, attached to a frame that takes care of the correct placement and removal of the filter.

WO 00/67668 discloses a Nitinol basket that forms the framework of the filter, and a separate polymer sheath is attached around this frame. At the proximal side, the sheath has large entrance ports for the blood and at the distal side a series of small holes filters out the emboli. This system, however, has some major disadvantages. First of all, the closed basket construction makes this filter frame rather rigid and therefore it is difficult to be used in tortuous arteries. At a curved part of an artery, it may even not fit well against the artery wall and will thus cause leakage along the outside of the filter.

Another disadvantage of such filters is there is a high risk of squeezing-out the caught debris upon removal, because the struts of the framework force the debris back in the proximal direction, while the volume of the basket frame decreases when the filter is collapsed. Further the construction makes it very difficult to reduce the profile upon placement of the filter. This is very critical, because these filters have to be advanced through critical areas in the artery, where angioplasty and/or stenting are necessary. Of course the catheter that holds this filter should be as small as possible then. In the just described filter miniaturization would be difficult because at a given cross section there is too much material. The metal frame is surrounded by polymer and in the center there is also a guide wire. During angioplasty and stenting, the movements of the guide wire will create further forces that influence the position and shape of the filter, which may cause problems with the proper sealing against the artery wall. This is also the case in strongly curved arteries.

In U.S. Pat. No. 6,348,062, a frame is placed proximal and a distal polymer filter membrane has the shape of a bag, attached to one or more frame loops, forming an entrance mouth for the distal filter bag. Here the bag is made of a very flexible polymer and the hole size is well defined. Upon removal, the frame is closed, thus closing the mouth of the bag and partly preventing the squeezing-out of debris. This is already better than for the full basket design, which was described above, where the storage capacity for debris of the collapsed basket is relatively small. The filter bag is attached to the frame at its proximal end and sometimes to a guide wire at its distal end. Attachment to the guide wire can be advantageous, because some pulling force may prevent bunching of the bag in the delivery catheter.

It may be clear that it is easier to pull a flexible folded bag through a small diameter hole, than to push it through. However, the deformation of the bag material should stay within certain limits.

If the filter is brought into a delivery sheath of small diameter, collapsing the frame and pulling the bag into the delivery sheath causes rather high forces on the connection sites of filter to frame and/or guide wire. While the metal parts of the frame slide easily through such a delivery sheath, the membrane material may have the tendency to stick and in the worst case it may even detach from the frame and tear upon placement or during use, because of too much friction, unlimited expansion, crack propagation etc.

The connection of the filter bag to the frame is rather rigid, because of the method of direct attachment. Additional flexibility, combined with a high strength attachment spot would also be advantageous.

Methods for making kink resistant reinforced catheters by embedding wire ribbons are described in PCT/US93/01310. There, a mandrel is coated with a thin layer of encapsulating material. Then, a means (e.g. a wire) for reinforcement is deposited around the encapsulating material and eventually a next layer of encapsulating material is coated over the previous layers, including the reinforcement means. Finally the mandrel is removed from the core of the catheter.

Materials for encapsulating are selected from the group consisting of polyesterurethane, polyetherurethane, aliphatic polyurethane, polyimide, polyetherimide, polycarbonate, polysiloxane, hydrophilic polyurethane, polyvinyls, latex and hydroxyethylmethacrylate.

Materials for the reinforcement wire are stainless steel, MP35, Nitinol, tungsten, platinum, Kevlar, nylon, polyester and acrylic. Kevlar is a Dupont product, made of long molecular highly oriented chains, produced from poly-paraphenylene terephalamide. It is well known for its high tensile strength and modulus of elasticity.

In U.S. application Ser. No. 09/537,461 the use of polyethylene with improved tensile properties is described. It is stated that high tenacity, high modulus yarns are used in medical implants and prosthetic devices. Properties and production methods for polyethylene yarns are disclosed.

U.S. Pat. No. 5,578,374 describes very low creep, ultra high modulus, low shrink, high tenacity polyolefin fibers having good strength retention at high temperatures, and methods to produce such fibers. In an example, the production of a poststretched braid, applied in particularly woven fabrics is described.

In US Published Application No. 2001/0034197, oriented fibers are used for reinforcing an endless belt, comprising a woven or non-woven fabric coated with a suitable polymer of a low hardness polyurethane membrane, in this case to make an endless belt for polishing silicon wafers. Examples are mentioned of suitable yarns like meta- or para-aramids such as KEVLAR, NOMEX OR TWARON; PBO or its derivatives; polyetherimide; polyimide; polyetherketone; PEEK; gel-spun UHMW polyethylene (such as DYNEEMA or SPECTRA); or polybenzimidazole; or other yarns commonly used in high-performance fabrics such as those for making aerospace parts. Mixtures or blends of any two or more yarns may be used, as may glass fibers (preferably sized), carbon or ceramic yarns including basalt or other rock fibers, or mixtures of such mineral fibers with synthetic polymer yarns. Any of the above yarns may be blended with organic yarns such as cotton.

BRIEF SUMMARY OF THE INVENTION

The present invention provides novel medical devices, such as vascular filters, with improved strength and flexibility and methods for their manufacture. These filters have a proximal frame section and a distal section, which can be collapsed into a small diameter delivery catheter and expanded upon release from this catheter. The proximal section is made as a frame of a relatively rigid material compared to the material of the distal section, for example a metal, and the distal section is provided with a flexible thin membrane, with perfusion holes in filter devices, of a diameter that allows blood to pass, but prevents the passage of emboli. The distal filter membrane has a proximal entrance mouth, which has almost the same size as the body lumen of a patient when the filter is deployed. The membrane is attached to the proximal section, which has the function to keep the mouth of the distal filter open and to prevent the passing of emboli between the body lumen wall and the edge of the filter mouth.

In order to have a good flexibility and a minimized crossing profile upon delivery, the membrane is made extremely thin. Tearing of the membrane is prevented by embedding in the filter membrane thin filaments of a material with high strength in the longitudinal direction, but high flexibility upon bending. Such a filter membrane with embedded filaments can have extreme flexibility and elasticity in certain directions, combined with limited deformation, high strength and prevention of crack propagation through the membrane material. Further, the filaments can be attached to the proximal frame section in such a way that the connection points act as hinges and as additional safety for the case that the membrane material might come loose from the frame.

The embedded filaments can include elements that help to give the membrane a desired shape after deployment.

The surface of the membrane filter may be coated with an additional material that improves the properties, for example the biocompatibility, drugs release or any other desired property, which the membrane itself does not offer.

The thus reinforced membranes can also be manufactured without holes for use for parts of catheters, inflatable parts, balloon pumps, replacement of body tissues, repair of body parts and functional parts like artificial valves and membranes, where minimal thickness and/or high strength are required.

Fibers are used not only as reinforcement for the membranes, but are also used as pulling fibers for the extraction the device from a delivery catheter or for retrieval, or retraction, of the device into a removal sheath. The frames can be used in temporary devices like a removable temporary stent, dilator, reamer, occlusion device for main artery or side artery, a housing for a graft, a valve, a delivery platform for drugs, radiation or gene therapy, or any other device that has to be placed and removed after some time. Applications are not restricted to arteries, but are meant for all body lumens.

Further, the invention provides a method for producing devices such as filters by dipping on a removable mold. According to this method, thin filaments of a material with high strength in the longitudinal direction, but high flexibility upon bending, are embedded in the filter membrane. The fibers are preferably less stretchable than the membrane material. The resulting composite membrane can have extreme flexibility and elasticity in certain directions, combined with limited deformation, high strength and prevention of crack propagation through the membrane material. Another function of the embedded filaments is that they help to give the membrane a desired shape after deployment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 28-31 are side elevational views showing four stages in the fabrication of a first embodiment of a filter according to the present invention.

FIG. 32 is an elevational view showing a second embodiment of a filter according to the present invention.

FIGS. 33-35 are side elevational views showing a third embodiment of a filter according to the present invention in three different stages of operation.

FIG. 35 a is a detail view of a portion of the third embodiment in the operation stage of FIG. 35.

FIG. 35 b is a detail view similar to that of FIG. 35 a showing a modified version of a component of the embodiment of FIGS. 33-35.

FIGS. 36 a and 36 b are detail views of a modified form of construction of a portion of the embodiment of FIGS. 33-35.

FIG. 37 is a side elevational view showing a modified version of the third embodiment and includes an inset illustrating the modification to a larger scale.

FIG. 38 is a side elevational view showing the filter of FIG. 37 in a further possible operating stage.

FIG. 39 is a side elevational view showing a fourth embodiment of a filter according to the present invention.

FIGS. 40-47 are pictorial views of successive stage is a procedure for treating an obstruction in a carotid artery according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The advantages of the invention will become more apparent after reference to the following detailed description. FIGS. 28-39 show filters that can serve as distal filters in the two-filter systems shown in FIGS. 1-27. However, the manufacturing techniques described below can also be used in the manufacture of proximal filters.

In the present specification, filters with improved flexibility and smaller profile are described. Such a filter basically has a proximal frame for expansion and contraction and, attached thereto, a thin filter bag that is made of two basic materials. One material is the highly flexible filter membrane itself, with a pattern of holes for allowing flow of blood particles below a well defined size, and the other material is a reinforcement made of fine fibers with high axial strength but thin enough to be flexible upon bending. The reinforcement is integrated with the membrane to create a composite structure with very flexible membrane areas where the blood is filtered and extremely strong reinforcement fibers that take up excessive forces to prevent the membrane from tearing even in response to pulling forces, and act as flexible hinges at the points of attachment to the proximal frame and/or to a guide wire. All of the fibers disclosed herein can consist of, or include Dyneema® fibers, manufactured by DSM High Performance Fibers, a subsidiary of DSM N.V. These are superstrong polyethylene fibers. The fibers can also be combined with fibers or wires of other materials, such as Nitinol, to help control the expanded shape of the filter

These fibers can be embedded in the membrane by a dipping or spraying process or they can be attached with glue, stitching, a solvent for the membrane material, heat, welding etc.

In order to achieve a better connection between the reinforcement fibers and the membrane material, the fibers may first be coated with a material that adheres well to the membrane material, for example with the same material as the membrane.

The fibers can be made of any strong and tough material, preferably a material with a modulus of elasticity that is higher than that of the surrounding membrane. The fibers can be made of round, flat or different shaped mono-filaments or multi-filaments and can include metal elements, for example titanium or Nitinol, carbon, boron, glass, or polymers, for example ultra high molecular weight polymers with extreme tensile strength and high modulus.

The fibers not only reinforce the membrane, but also can be used to control the final geometry, prevent crack propagation, act as hinges at the place of attachment to the frame and prevent loss of the membrane or parts of it.

Because the reinforcement the membrane itself can be made much thinner than known membranes, the crossing profile of the composite filter can be much lower than for a single polymer membrane, even if the reinforcement fibers are thicker than the membrane itself.

A method according to the invention for making a reinforced filter is carried out by first providing a paraffin mold having the desired shape of the expanded, or deployed, filter bag. Then the mold is covered with a polymer skin, which will subsequently detach easily from the membrane polymer. This paraffin mold, covered with the polymer skin, is dipped in a solution of polymer and solvent until a layer of membrane polymer is created. After that step, the frame is placed around the mold and reinforcement fibers, possibly coated, are then mounted to the frame at the hinge sites and laid over the surface of the mold. Another dipping step in the solution of polymer and solvent ensures full embedding of the fibers into the growing membrane polymer layer. Finally, the perfusion hole pattern is laser drilled into the membrane and the last step is the removal of the paraffin by melting it out in warm water. The polymer skin can then be easily detached from the inside of the filter membrane and pulled out

With the use of a paraffin mold it is possible to make complicated or very simple designs, because there is no need to remove a relatively large mandrel from the filter after it has been made. This would be complicated if the mandrel was for example a metal or polymer part, which had to be pulled through some openings at the proximal side.

Paraffin is of course not the only material that can be used for a mold. Any material that can be brought into the desired shape and can be dipped directly or after application an intermediate layer may be used. Examples are meltable materials or materials that easily dissolve in water, like salt or sugar crystals. Other examples are fine grains in a vacuum bag or an inflated balloon which is deflated after dipping. It is also possible, for certain filter embodiments, to use a mold that can be safely removed without being melted, dissolved, or deformed.

Fibers are also used for enabling the removal of an expandable device by pulling the device into a removal sheath.

The principles of the disclosed invention become clear from the following description of the figures. Identical parts in different figures are given the same reference number.

FIG. 28 shows a paraffin mold 401, made in the desired filter shape. Paraffin is chosen because it can be removed from the filter easily, at a temperature that does not cause degradation of the polyurethane of the filter.

However, dipping of the paraffin mold directly into the polyurethane has been found to not give the best results. Therefore, paraffin mold is first covered with a thin sheet 402 of polyvinyl alcohol. The polyvinyl alcohol is a thin sheet that can be stretched after wetting with water and pulled tight around the paraffin and then tied together with a small clip or wire 403. Then, the resulting assembly is dipped a few times in a solution of polyurethane in tetrahydrofuran, thus building a layer of polyurethane of, e.g., 3 microns in thickness at the right side of the dipping line.

FIG. 29 shows a Nitinol frame 420 made from tubing having an outer diameter of 0.8 mm by laser cutting and shape setting. At the proximal side, which is on the left, the tube end 425 is uncut and still 0.8 mm. in diameter. From there, the tube is cut to form eight longitudinal spokes 426 that end in a zigzag section with struts 427, where the unconstrained, expanded material of frame 420 lies on a circle having a diameter is 8 mm at its largest point. This frame 420 will, at any size between the maximum diameter and the collapsed size of 0.8 mm diameter, always adapt smoothly to the given geometry of the body lumen, such as an artery. The mold of FIG. 28 is placed inside this frame and eight reinforcement fibers 428 of, for example, multifilament ultra high molecular weight polymer are attached to the most distal section of the Nitinol frame 420 at points 429. Fibers 428 can be attached to frame 420 by means of a knot or each fiber can just be run back and forth from the distal tip to the a point 429 and wrapped around the Nitinol frame at point 429. In the latter case, each fiber 428 will have twice the length shown.

At the distal end, i.e., the right-hand end, of the assembly, all fibers come together in a guide ring or tube 430, where they are held in correct position for the further dipping operation.

FIG. 30 shows the mold with the Nitinol frame and the surrounding fibers after having been dipped several more times until the fibers are well embedded in the polyurethane membrane, for example until the layer of polyurethane is 5 microns thick at places 431 where no reinforcement fibers 428 are present. Of course the thickness at the places 432 where these fibers are present is greater than at places 431, dependent on the type of fibers and the number of dipping steps. Guide tube 430 of FIG. 29 is removed after the dipping is finished and the membrane is dry.

FIG. 31 shows the final filter 440, with a pattern of holes 441 each 100 microns in diameter, which have been laser drilled between the reinforcement fibers 428. After drilling of the holes, the central paraffin mold 401 is removed by melting in warm water, which can be at a temperature of 50° C. The polyvinyl alcohol layer is easily released from the polyurethane filter membrane and is removed. Further, the fibers 428 are cut to the correct length at point 442 and attached to a central guide wire 443 in a connector 444 in the form of a nose tip that fits on top of the delivery catheter if the filter is retracted into this catheter before placement into the body lumen of the patient. Note that the polyurethane membrane between the Nitinol struts 427 at the distal end of frame 420 is also removed, in the spaces enclosed by struts 427 and the dipping line, preferably by laser cutting.

This construction is extremely strong and still very flexible. The 5 micron thick membrane with the reinforcement fibers 428 fits easily in a delivery catheter of only 0.9 mm inner diameter and adapts to all sizes of arteries between 1 and 8 mm diameter.

The central guide wire 443 extends to the left from connector 444 through the membrane and frame 420, including the uncut part of tubing 425. Within connector 444, fibers 428 are wrapped around, and secured to, guide wire 443. To remove the filter from a delivery catheter, guide wire 442 is pushed from its proximal end (not shown-to the left in FIG. 31) so that a pulling force is exerted on fibers 428 due to their connection to guide wire 443 in connector 444. Thus, all tension forces on the distal section of the filter are taken up by the reinforcement fibers 428. The membrane only has to follow these fibers and unfold as soon as it leaves the catheter. The filter opens because of the elasticity of Nitinol frame 420. Also the blood pressure in the artery further helps to open the filter like a parachute. Upon bending of the filter there is almost no force needed at the sites where fibers are attached to the Nitinol struts, so these sites act as hinges. Even in strongly curved arteries the filter frame still adapts well to the artery wall and there is almost no blood leakage between the membrane and artery wall.

The fibers are so well embedded in the polyurethane membrane that in case the membrane detaches from a Nitinol frame strut, the membrane will still have a strong connection to the frame and can be collapsed and removed from the patient safely.

In case of a tear in the membrane, for example starting from a 100 micron hole, this membrane may tear further, but only until the tear meets a fiber. There the tear will stop, and the membrane can be removed safely and completely as well. Of course this situation is very undesirable and the loss of some entrapped emboli may be the consequence, but at least the removal of the filter itself would not cause problems.

After a medical procedure has been performed, the Nitinol frame can be collapsed to close the mouth of the filter and entrapped emboli cannot leave this closed filter bag anymore. The hinges guarantee now that the filled bag hangs at the distal end of the removal catheter and still can move easily through curved arteries.

The reinforcement fibers can be used not only for their high tensile strength. They can also be combined with memory metal wires, or filaments, made, for example, of Nitinol wires that can be shape set to almost any desired shape by heat treatment. Such wires may be embedded in or attached to the membrane to guarantee a smooth folding/unfolding of the membrane. An example is an embedded Nitinol wire that helps to give the mouth of the filter membrane a smooth geometry that fits well to the artery wall. Such a Nitinol wire for shape control can be combined with a more flexible, but stronger, fiber, which is used to protect the membrane against incidental overload, tear propagation or any of the described problems in non-reinforced membranes.

The orientation and number of the reinforcement fibers is not limited and can vary with the desired application.

In FIG. 32 a distal filter 450 is shown, with a conical shaped filter membrane 451, attached to the same proximal wire frame 420 as in FIGS. 29-31. In this example, however, the membrane is not attached directly to the Nitinol frame. It is attached, for example, by guiding a single, long reinforcement fiber 452 from the distal end at an angle with the cone surface until it reaches the Nitinol struts 427 at points 429, then wrapping fiber 452 around one of these struts at a point 429 and guiding the fiber back to the distal tip with a reverse angle and repeating this operation several times. Arrows in the drawing show how fiber 452 runs back and forth. By this method the use of knots at the fiber-Nitinol connection is redundant and the safety is further increased, because the filter can never detach from the frame. In this embodiment, membrane 451 can also be formed by dipping a suitably shaped mold in a solution of polymer and solvent.

A guide wire 453 is fastened to fiber 452 at at least one point at the distal end of the filter and extends through the filter to a proximal end thereof (not shown—to the left in FIG. 32).

The pattern with crossing reinforcement fibers gives the filter membrane different elastic properties and gives the benefit of an improved, but limited axial elasticity.

The pattern of filter holes, preferably cut by laser, can be made in zones between the fibers to avoid damaging the fibers.

However, if the pattern of reinforcement fibers is very fine, the holes may just be cut without regard for the locations of these fibers. There will then still be enough reinforcement left, because adjacent crossing, parallel or angled uncut fibers can take over some forces via the embedding material of the membrane itself.

The conical filter shape has the following advantages. If this filter has a maximum, expanded, diameter of 8 mm and is placed in an artery of 8 mm diameter, all holes will be free from the artery wall and blood can flow through all holes. As soon as particles of debris, like emboli, are entrapped, they will tend to collect at the most distal tip, leaving the more proximal holes open.

The area of the conical surface of the cone relates to the cross-sectional area of the artery as the length of the cone edge from base to tip relates to the radius of the artery. Preferably, the total surface area of the holes should be at least equal to the cross-sectional area of the artery in order to guarantee an almost undistorted blood flow. This is the case if the ratio of the total surface area of the cone surface to the total hole surface area is smaller than the ratio of the cone surface area to the cross-sectional area of the artery, or, in other words, the total surface are of the holes is at least equal to the cross-sectional area of the artery.

For an artery having an inner diameter of 8 mm, a total number of 6400 holes each with a 100 micron diameter is needed for the same surface area. Of course, the type of flow through small 100 micron diameter holes is different from the undistorted flow through an open artery. However, because the wall thickness of a reinforced membrane according to the invention can be extremely small, the length of a hole (for example only 5 microns) ensures a much better flow than compared to a 100 micron hole in a thick membrane.

A filter made in conical shape will also have enough free holes if it is used in arteries with smaller diameter. The holes that touch the artery wall will not contribute to the flow, but the remaining free holes still have the same surface area as the actual cross section of the smaller artery.

Filters according to this invention are so much more flexible than existing filters that they can be made longer without creating problems in strong curves. Therefore they can have greater storage capacity for emboli.

If the reinforced membrane and the filter frame are mounted to each other without overlap, as in FIG. 32, it may be clear that the collapsed diameter can be made smaller than in the case of, for example, FIG. 31.

Here, at a specific cross section of the Nitinol frame near the attachment points 429, the Nitinol frame, the membrane, the fibers and a central guide wire 453 all take their part of the available cross section in the delivery sheath. It depends on the demands if this is allowable, or if a design should be chosen without overlap, where frame and membrane are separated by the fiber hinges, thus reducing the size.

The construction of Nitinol frame 420 has certain advantages. Production of the frame is very simple, the guide wire is kept in the center, and the filter can be pulled out of the delivery sheath by pushing on guide wire 453 from the left to exert a pulling force on fiber 452 and membrane 451.

During removal of the filter from an artery, the longitudinal spokes 426 of frame 420 just have to pull the struts 427 of the zigzag section into a removal sheath.

However, such a frame can also have some disadvantages. In strongly curved arteries the guide wire will bend and it will cause forces that may deform the zigzag struts. Eventually the contact with the wall of the artery is not optimal then, which is undesirable.

Another disadvantage is that axial movements of the guide wire, for example caused by the angioplasty/stenting procedure can influence the position of the filter. It would be better if the guide wire could move freely over at least a certain axial length plus in radial and tangential directions within the entire cross section of the filter, without exerting any force on the expanded frame.

In FIGS. 33-36 an embodiment with such a freely movable guide wire is disclosed.

FIG. 33 shows a filter 460 that is constructed in such a way that it can be delivered from a delivery sheath by pushing on a guide wire 461 to exert a pulling force on the filter. After completion of use of the filter in a medical procedure, the filter is removed by pulling it into a removal sheath with the aid of guide wire 461. The pulling forces are applied in both directions by moving guide wire 461 in axial direction relative to the sheath.

Guide wire 461 runs through the filter and ends at distal section 462. Fastened to guide wire 461 are stops 463 and 464 that have a larger diameter than the guide wire itself. These stops are connected tightly to the guide wire by any known technique. At the distal tip of filter 460, a ring 465 is fastened to the filter and guide wire 461 can slide freely through ring 465, until stop 463 touches ring 465.

At the proximal side of stop 464, a second slide ring 466 is mounted around guide wire 461 to allow guide wire 461 to slide freely therethrough. Slide rings 465 and 466 are given a smooth shape with rounded edges to let the move easily in associated sheaths and in the artery.

The filter membrane 470 is connected directly to slide ring 465 and reinforcement fibers 471 are also attached tightly to ring 465. At the other side, reinforcement fibers 471 are connected to an expandable frame 480 at connection points 481, possibly together with the membrane material itself.

Expandable frame 480 is provided with points of attachment 482 at its proximal side, which are needed to pull the frame back into a removal sheath, such as sheath 490 in FIG. 34. Flexible fibers 483 are connected to these points 482 and run to the proximal slide ring 466, to which they are securely attached.

If the guide wire is moved through the filter in the proximal direction, i.e., to the left in FIGS. 33-35, stop 464 will move freely over a distance X₁ before it touches slide ring 466, and fibers 483 become stretched.

If the guide wire is moved through the filter in the distal direction, i.e., to the right in FIGS. 33-35, stop 463 will move freely over a distance X₂ before it touches slide ring 465. Fibers 483 will hang free than, because there is no axial force on slide ring 466. This means that, when the filter has been placed in an artery, guide wire 461 can move freely in the cross-sectional area of the filter frame in both radial and tangential directions without exerting any forces on this frame. Further, the guide wire can also move back and forth over a total distance X (=X₁+X₂) in the longitudinal direction relative to the filter, before it influences the shape or axial position of the filter in the artery. Distance X can be changed by choosing the distance between fixed stops 463 and 464. If one of these stops is removed, distance X is maximized. Of course the distal end section 462 of guide wire 461 must then be long enough to prevent slide ring 465 from disengaging from the guide wire tip.

With the construction of slide rings 465 and 466 on guide wire 461, the guide wire can be rotated around its length axis without influencing the position and shape of the filter and its frame.

All of these degrees of freedom enable the operator to use guide wire 461 for angioplasty/stenting procedures without influencing the shape and position of the distal filter. This is extremely important.

Further, this design allows the length of Nitinol frame 480 to be shortened and thus it makes the filter more flexible and more easily usable in strongly bent arteries and arteries with limited space for the filter, in view of the high degree of flexibility of membrane 470 and fibers 471 and 483. In a strongly curved artery, guide wire 461 may even touch the inner wall of frame 480, without exerting relevant forces on the filter. Even with a strongly bent guide wire, the filter will still maintain its full contact with the artery wall and guarantee a safe functioning of the device for a wide range of artery diameters and geometries.

As can be seen from a comparison of FIG. 33 with FIGS. 31 and 32, the design of FIG. 33 gives a much smaller proximal surface of the expanded frame. In FIGS. 29-32, the Nitinol spokes 426 and the proximal side of tube section 425 have a certain surface area that reduces blood flow. This surface area is much smaller in FIG. 33, because only a few thin fibers 483 are interposed in the blood flow.

Another advantage is that debris in the blood will less likely adhere to the thin fibers than to the proximal side of parts 425 and 426 of FIGS. 29-32. Of course, an additional treatment of these fibers to reduce the tendency of blood cells to adhere thereto is helpful and is a part of this invention as well. The material for these fibers can be of any kind, and they can for example made of the same materials as the reinforcement wires for the filter membrane.

An example would be a composite fiber made of a Nitinol filament core, surrounded by a multifilament ultra high molecular weight highly oriented polymer. The Nitinol can be used to give some shape control to the wire, for example to prevent adjacent fibers from becoming entangled. The polymer multifilament, besides having high strength and low strain, can have for example anti-thrombogenic agents embedded therein.

In FIG. 34 the filter of FIG. 33 is shown in a stage in which it is being delivered from a delivery sheath 490. Sheath 490 has a wall 491 and a distal end 492. At the proximal side of the guide wire 461 a pushing force F is applied in the distal direction, while sheath 490 is being pulled back in the proximal direction, or is being held in place. Stop 463 on guide wire 461 is now in direct contact with slide ring 465, and force F is transferred by this ring to the reinforcement fibers 471 of the filter membrane 470. By the resulting pulling force in the filter membrane and fibers 471, the filter membrane is stretched and this pulling force is transferred to the collapsed frame 480 via connection points 481. The frame and filter membrane will easily slide out of sheath 490 by this pulling force, followed by the unloaded fibers 483 and slide ring 466. As can be seen, the proximal section 482 of frame 480, to which the fibers 483 are attached, is slightly bent inwards to create a conical proximal side of frame 480.

FIG. 35 shows the filter in a position to be retracted into a removal sheath 500. Removal sheath 500 has a wall 493 and a distal end 494. At distal end 494, the removal sheath may have a flared end section 495, as shown in FIG. 35 a, a chamfered wall 496, as shown in FIG. 35 b, or a combination thereof. Distal end 494 must enable the retrieval of the filter into the lumen of sheath 500 by a pulling force, which is applied to the proximal end of guide wire 461 while sheath 500 is being moved in the distal direction or is being held in place. The tapered proximal side 482 of the frame also assists withdrawal of the frame into removal sheath 500.

The force F₁, applied to guide wire 461, is transferred by stop 464 to slide ring 466, which distributes the force to fibers 483 that are now pulling on the proximal side 482 of frame 480.

The wire ends can be attached by any technique that is available, for example by putting them through respective holes 484 in frame 480, and securing them by a knot 485 on the inside surface of the frame. The proximal tips 486 of frame 480 have been formed in such a way that they are slightly curved inside with a conical top angle that is larger than the top angle of the cone, described by the stretched fibers 483, just before the parts 486 enter into removal sheath 493. This is done to prevent these proximal sections from becoming stuck at the distal end 494 of the removal sheath.

With the tapered shape of frame 480, the tension force in fibers 483 will easily make it possible to slide the removal sheath over the frame until it is completely covered by this sheath. Filter membrane 470, eventually filled with embolic debris, does not have to be pulled into this sheath completely. It can extend from the distal end 494 while the whole device is removed from the artery.

FIGS. 36 a and 36 b are side views of an alternative embodiment 510 of the filter frame, in its expanded and collapsed shapes, respectively. This embodiment is shorter than the embodiment of FIGS. 33-35, and, in particular, lacks the distal end portion of the embodiment of FIGS. 33-35. In FIGS. 36 a and 36 b, frame 510 is composed of struts configured in a zigzag-pattern. Here again the proximal side 512 is curved inwardly with curved tips 516 and it has attachment holes 514 for the fibers.

The fact that the filter frame is not subjected to a pushing force during deployment from, or retraction into, a sheath enables a further downscaling of the frame struts and thus a miniaturization of the delivery profile of the device. This is also enhanced by the fact that the guide wire does not influence the shape and position of the filter upon angioplasty and stenting, so the frame itself can now also be made lighter.

In FIG. 37, another embodiment of the filter frame 520 is shown. Elongated attachment parts 526 are formed at the proximal side 512 of the frame 520 in order to bring the holes 524 for the attachment of the fibers 483 further away from the expandable and collapsible unit cells of the frame. This increased length helps to achieve a smoother shape upon shape setting, so that these struts will have the desired curvature that is needed to slide easily into the removal sheath. Placement of the attachment holes at the very proximal tip of the frame struts will also help to allow the frame to be pulled back into the removal sheath without the risk of getting stuck at the entrance of this sheath.

The elongated struts forming frame 520 can be shape set into almost any desirable angle. A part of the struts may be parallel with the length axis of the filter, while another part or parts may be angled inside or outside, as needed for smooth removal of the device. Outside angled tips may even help to anchor the frame in the blood vessel for more axial stability.

FIG. 38 shows another feature of the present invention. The design of a filter according to the invention with flexible fibers 483 makes it possible to push a tube 530 over guide wire 461 until the distal end 531 of tube 530 reaches deep into the filter.

The fibers 483 will easily move with distal end 531 of tube 530 and, dependant on the length of these fibers, the most distal position of tube end 531 can be chosen. This positioning of a tube inside or beyond the frame 520 opens the possibility of flushing and/or suction through it in order to move debris either deeper into the distal end of the filter or to suction debris out of the filter. Flushing with certain liquids can also help to make the debris smaller. An additional treatment device can also be inserted through tube 530 inside the filter. This additional treatment device can be any means for inspection, measuring or all kinds of treatments like breaking up of clots by mechanical means, laser, ultrasonics, etc. Also additional retrieval devices may be brought into the filter through tube 530. Of course, tube 530 may be the same tube as the removal sheath, in order to save components and to reduce operating time.

FIG. 39 shows another embodiment for the shape of a filter 470, with an additional reservoir 472 for storage of debris. Because the conical filters of FIGS. 33-38 have a tip with limited space to store debris, the filter may be filled too soon, which may cause problems with maintaining a satisfactory blood flow through the filter.

Normally it can be expected that the major part of the debris will collect most distally, leaving the most proximal holes open for blood flow. This can be improved by providing additional reservoir 472, which is connected to the conical section 473 by a portion 474. If the diameter of reservoir 472 is half the maximum diameter of the frame, the surface area that remains free for blood flow between the wall of the full reservoir and the artery wall is still 75% of the maximum surface area of the artery. The capacity of reservoir 472 can be chosen so that the closure of filter holes in section 473 by abundant debris is most unlikely. Additional flushing and/or suction as described with references to FIG. 38, may further help here. Of course, continuous monitoring of the blood flow beyond the distal end of the filter will give the necessary information if the situation becomes critical and the filter must be removed.

The shape and diameter of reservoir 472 will be dependent on the expected diameter and geometry of the artery that will be treated. The shape of reservoir 472 can be determined by embedded fibers. The membrane may for example be elastic, while the fibers can have a limited stretchability. Dependent on the pressure inside the reservoir, the diameter of the membrane can be made to vary until it reaches a certain predetermined value, when the embedded fibers reach their strain limit. Such embedded diameter limiting fibers will have a more or less tangential orientation.

Frames as shown in FIGS. 33-39 and described above may not only be used in application of filters. They can also be used as a removable temporary stent, dilator, reamer, occlusion device for main artery or side artery, a housing for a graft, a valve, a delivery platform for drugs, radiation or gene therapy, or any other device that has to be placed and removed after some time. Applications are not restricted to arteries, but are meant for all body lumens.

A filter according to the invention, particularly because of the flexibility of the fibers, allows an element, such as tube 530 of FIG. 38, to penetrate into the region enclosed by the membrane structure to apply suction to debris contained in the filter bag either continuously or intermittently. This is particularly applicable to the distal filter of a two filter assembly. The tube can be introduced over a guide wire associated with the filter and can enter the filter with no risk of perforating it. The safety of applying suction to the interior of the filter is ensured by the nature of the material used for the membrane and reinforcing fibers, as described above with reference to FIGS. 28-29. Such suction allows the filter to be maintained relatively free of debris and helps to achieve a relative stability in blood flow through the membrane. In addition, the suction element enables the filter to be kept in a relatively empty condition prior to its being closed and withdrawn and prior to the use of a distal retrieval filter.

Membranes according to the invention can be used, without holes, as skin for grafts, stents, heart valve tissues, etc.

The following Figures show a device bearing certain similarities to that shown in FIG. 9 and having components shown in other Figures that have already been described herein. Components and body features identical to those of FIG. 9 and the other Figures will be identified with the same reference numerals as those used in FIG. 9.

The start of a procedure according to the invention is shown in FIG. 40. First, a sheath, or guiding catheter, 68 carrying a surrounding balloon 72 near its distal end is introduced into common carotid artery (CCA) 70 by a conventional angiographic procedure. Balloon 72 is initially deflated. Guiding catheter 68 preferably has a diameter of 8-9Fr (3Fr=1 mm).

The next step is the introduction of a filter into the external carotid artery. Customarily, the external carotid artery may have a tortuous course and its location is established initially by the use of a combination of a guide wire 600 and a sheath 10, which may have a diameter of 3Fr. Guide wire 600 can be radiolucent and non-traumatic and can be positioned with the sheath accurately within the external carotid artery.

After this position has been established, guide wire 600 can be withdrawn and a filter 601 carried by a guide wire 2 having a distal extension 2′ is placed in the external carotid artery 66 through sheath 10. Then sheath 10 is withdrawn to deploy, or expand, filter 601 in order trap any debris from the subsequent angioplasty procedure while allowing at least a limited blood flow past filter 601. This procedure is shown in FIG. 41. Guide wire 2 and extension 2′ are each provided with a bead, as shown in FIG. 41, to hold filter 601 in place. Filter 601 may be provided with a filter sheet having a pore size of 100 μm.

At this stage, blood flow is antegrade, i.e., in the normal forward flow direction, in CCA 70, ICA 64 and ECA 66.

Filter 601 preferably has any of the forms shown in attached FIGS. 7 and 28-39.

Sheath 10 is withdrawn from the patient's body to assure that space is available in sheath 68 for subsequent insertion of other catheters.

In the next part of the procedure, as shown in FIG. 42, a further guide wire 602 is introduced through sheath 68 into ICA 64, past the site of obstruction 62 and an angioplasty catheter 604 carrying a stent 606 is introduced over guide wire 602 to bring stent 606 in line with obstruction 62. For locating the internal carotid and dealing with technical difficulties of intubation this introduction may need to be carried out in exactly the same way as described above with respect to the introduction of filter 601 in ECA 66. Guide wire 602 can be a hollow guide wire connected to a pressure gauge to allow the pressure in ICA 64 to be monitored.

Catheter 604 typically carries a stent deployment balloon that is expanded after catheter 604 has been properly positioned, to expand and deploy stent 606 in order to alleviate the blockage caused by obstruction 62. Initially, the balloon carried by catheter 604 is deflated.

The blood flow continues to be antegrade.

Then, as shown in FIG. 43, balloon 72 is inflated to block blood flow in CCA 70 around sheath 68, thereby essentially blocking most or all of antegrade blood flow in arteries 64, 66 and 70. This allows possible retrograde flow in the ICA and/or ECA. If at this time ICA 64 is not completely blocked, some retrograde flow may occur therein and will result in minimal antegrade flow into ECA 66. The reason for this assumption is that, ordinarily, blood flow, antegrade or retrograde, in an unobstructed ICA is approximately 3 times that into the ECA and the presence of a filter in the ECA would be expected to reduce flow through the ECA further. Hence, although the retrograde flow from the ICA will initially tend to stagnate in the intermediate part of the carotids between the ICA and ECA, one would expect that if flow occurs from the ICA to ECA, it would be minimal. Equally, the argument cant be made that in the presence of a high grade block in ICA 64, some minimal blood flow can occur from the ECA to ICA which, the presence of a filter, acting as a resistance and being used for this purpose, will tend to negate.

After inflation of balloon 72 to block blood flow in CCA 70 around sheath 68 (blood flow within sheath is prevented by sealing the proximal end of sheath 68), the balloon carried by catheter 604 is expanded to expand and deploy stent 606 in a manner to compress and at least partially disintegrate obstruction 62. The resulting debris tends to be trapped between filter 601 in ECA 66, balloon 72 and and the balloon on catheter 602.

The balloon carried by catheter 604 is then deflated after stent deployment. It is to be noted that, ordinarily, retrograde flow would cease when CCA 70 is blocked. However, in the apparatus described, upon partial withdrawal of catheter 604, it can be utilized to perform low grade suction from outside the body of stagnant blood and debris in the area between the ICA, CCA and blocking balloon 72. Specifically, suction can be applied by a suction device connected to the proximal end of catheter 604, from a location outside of the patient's body, as shown in FIG. 43. If, for some reason, the suction provided through catheter 604 is inadequate, catheter 604 can be withdrawn completely from the patient's body and rapidly exchanged with a 6 F, non-tapered sheath inserted over guide wire 602 and advanced to the top of sheath 68. Controlled suction can then be resumed through that catheter into the suction device until particulate material and clots are evacuated. Furthermore, drugs such as heparin and other antithrombotic agents, for example Bivalarudin, can be introduced into the arteries through that catheter to allow any clots that have formed to be disintegrated. The drugs used can be other than the one mentioned but would need to be capable of clot dissolution. Using this technique of suction would also promote continued retrograde flow and avoid stagnation, and thereby, reduce the possibility of more clots forming. The material that is suctioned can be readily examined under a microscope and analyzed for debris size, content, and character. The reason for using low pressure suction is to prevent collapse of the stent or stents.

The presence of filter 601 in ECA 66 will markedly diminish retrograde flow and can serve to prevent a flow from ECA to ICA. Thus, it acts as a partial obstruction. For practical purposes, any retrograde flow from ICA 64 to ECA 66 will result in trapping of debris in filter 601.

Then, angioplasty stent catheter 604, or the above-mentioned non-tapered sheath, is withdrawn from the patient's body and, as shown in FIG. 44, a 3Fr sheath 610 is introduced into ICA 64 over guide wire 602 past stent 606. Guide wire 602 is then withdrawn from the patient's body and, as shown in FIG. 45, a second filter 620, identical to any of the filters disclosed herein, is introduced through sheath 610 by a procedure identical to that utilized for introducing a filter into the ECA, as described above, after which that sheath is pulled back to carefully deploy filter 620, using radiological verification beyond the stent, at a location past stent 606 and allow the filter to expand in order to trap any debris that may subsequently flow in the antegrade direction. In this stage, sheath 10 can be reintroduced at least into CCA 70, as shown in FIG. 44.

Sheath 610 can now be withdrawn or left in.

After both filters are safely deployed and are stable, antegrade flow is allowed to resume by deflating balloon 72. FIG. 46 shows debris captured by filters 601 and 620. The purpose of the two filters is to protect the cerebral circulation from embolization through either the internal carotid or, less commonly, through the external carotid, both arteries having been shown to have communications with the brain and the eyes.

If the patient is hemodynamically stable and has no evidence of stroke objectively determined by well known techniques such as transcranial doppler of the brain and clinical evaluation, each filter can be withdrawn using its respective introductory sheath to end the procedure. This is done, as shown in FIG. 47, by merely advancing, or reintroducing, sheaths 10 and 610 to capture and thus retract filters 601 and 620, filter 601 preferably being withdrawn first. Then sheaths 10 and 610 are completely removed from the patient's body, followed by withdrawal of sheath 68 from the patient's body.

According to a further feature of the invention, suction may be applied to ICA 64 through sheath 610 after angioplasty catheter 604 has been withdrawn from the patient's body, i.e., at the stage shown in FIG. 44, when balloon 72 is still inflated, and/or, through sheath 10 after it has been reintroduced at some point following withdrawal of catheter 604. This provides added assurance of complete removal of debris resulting from the angioplasty procedure.

Suction can also be applied directly through sheath 68.

Introduction of all illustrated components into the arteries can be effected according to conventional techniques through a conventional manifold.

While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.

The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

1. A method for treating a patient having an obstruction on a wall of a first blood vessel through which blood normally flows in a given direction, at a location downstream of a branch point where the first blood vessel and, a second blood vessel branch off from a main blood vessel, said method comprising: blocking blood flow in the main blood vessel at a point upstream of the branch point, with respect to the antegrade direction of blood flow; inserting into the second blood vessel a first filter adapted to pass blood while trapping debris resulting from removal of the obstruction; inserting an obstruction removal assembly into the first blood vessel and operating the assembly to at least partially break up the obstruction and produce debris; after operating the obstruction removal assembly, withdrawing the obstruction removal assembly from the patient's body and then inserting into the first blood vessel a second filter adapted to pass blood while trapping debris that results from removal of the obstruction; after inserting the first and second filters, restoring blood flow in the main blood vessel; and withdrawing the first and second filters from the patient's body together with trapped debris.
 2. The method of claim 1, wherein the first blood vessel is an internal carotid artery and the second blood vessel is an external carotid artery
 3. The method of claim 2 wherein the main blood vessel is a common carotid artery and said step of blocking blood flow is performed in the common carotid artery.
 4. The method of claim 2 wherein said step of inserting a removal device obstruction comprises: introducing a guide wire through a guide catheter into the first blood vessel; and then introducing the removal assembly over the guide wire to the site of the obstruction.
 5. The method of claim 1, further comprising, during a time when blood flow in the main blood vessel is blocked, applying suction to a region that contains debris produced from the obstruction.
 6. The method of claim 5, wherein said step of applying suction is carried by operating a suction device located outside of the patient's body and placing the suction device in communication, through a tube, with the region that contains debris produced from the obstruction.
 7. Apparatus for carrying out the method of claim 1, comprising: a guide catheter insertable into the first blood vessel to a point upstream of the branch point; first and second filters insertable through said guide catheter for trapping debris; a guide wire insertable through the guide catheter into the first blood vessel to a location downstream of the branch point; and an obstruction removal assembly insertable into the first blood vessel over the guide wire to the location of the obstruction.
 8. The apparatus of claim 7, further comprising a blocking balloon carried by said guide catheter, said blocking balloon being inflatable to perform the step of blocking blood flow. 